CN109596709B - Detection method of fixed pressure container - Google Patents
Detection method of fixed pressure container Download PDFInfo
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- CN109596709B CN109596709B CN201811553330.8A CN201811553330A CN109596709B CN 109596709 B CN109596709 B CN 109596709B CN 201811553330 A CN201811553330 A CN 201811553330A CN 109596709 B CN109596709 B CN 109596709B
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/04—Analysing solids
- G01N29/048—Marking the faulty objects
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B17/00—Measuring arrangements characterised by the use of infrasonic, sonic or ultrasonic vibrations
Abstract
The invention relates to a method for testing a stationary pressure vessel, by first calculating the theoretical thinnest permissible wall thickness D of the pressure vessel1Measuring the thickness of the fixed pressure container by using a thickness gauge, and calculating the average actual wall thickness D of the container2Comparison of the average actual wall thickness D2And the thinnest allowable wall thickness D1Judging the safety condition of the container, if the safety condition is safe, further carrying out full wall surface scanning on the pressure container by using an ultrasonic measurement method, determining the existing defects, positioning all the defects and marking; ultrasonic time difference diffraction detection is carried out on the position with the defect, the length and the height of the defect are obtained, the simulation size is calculated according to the length and the height of the defect, the crack with the maximum simulation size is screened out and is recorded as the maximum simulation size D for the defect3And the average actual wall thickness D2And comparing, and predicting the crack propagation rate and the residual service life of the safe container by a Paris formula, wherein the method provides an important basis for predicting the safety performance of the fixed pressure container and preventing leakage or explosion accidents.
Description
Technical Field
The invention relates to a detection method of a pressure container, in particular to a nondestructive detection method of a fixed pressure container.
Background
The pressure container is a special pressure-bearing device with explosion danger, is usually used for storing flammable, explosive and toxic liquid, gas and the like, and once explosion or leakage occurs, the consequences are extremely serious. In recent years, along with the continuous development of modern industry in China, stricter requirements on the product quality, the structure safety, the use reliability and the like of a pressure container are provided, and the safety and reliability judgment of a fixed pressure container is particularly important. During the application of the fixed pressure container, under the influence of factors such as temperature, medium, pressure and the like, various damages can be caused gradually, and the problem of stress concentration is easy to occur, and the problem is caused because certain residual stress exists in the welding seam of the structure body such as the internal connecting pipe, the end socket and the like, and the discontinuity and the like exist, so that the stress concentration is caused. Generally, damage, fatigue, cracking, corrosion, and the like occur at a stress concentration portion under the combined action of pressure such as temperature and medium, which leads to a great reduction in the usability of the pressure vessel. Therefore, national characteristics set out 'fixed pressure vessel safety technical inspection regulations' for carrying out standardized detection on the fixed pressure vessel.
The existing nondestructive detection method for the pressure container mainly comprises a TOFD diffraction time difference method ultrasonic detection technology, an acoustic emission detection method, a ray detection method and a magnetic powder detection method. These methods are all directed to detecting a certain portion of a pressure vessel or detecting a region of a crack, but neither qualitative nor quantitative data is accurate enough. For example, in CN102539533A, the weld joint of the large spiral shell is detected by TOFD method, and the weld joint is detected by TOFD, RT and UT comparative tests; CN103868985B discloses a method for quantitatively and comprehensively evaluating the defects of an in-service pressure vessel, which adopts a magnetic memory detection result to simulate a failure evaluation curve equation and comprehensively evaluate the safety of the in-service pressure vessel. CN105259180B discloses a crack propagation condition monitoring system for a pressure vessel containing longitudinal internal crack defects, which measures stress strain through a sensor, calculates stress strength and fracture toughness, and compares the stress strain with the fracture toughness to obtain the propagation condition of cracks. These prior arts cannot rapidly determine the defects of the fixed pressure vessel, and further, cannot give specific and detailed comprehensive determination criteria.
Disclosure of Invention
The present invention is directed to overcoming the above-mentioned deficiencies in the art and providing a comprehensive method for testing a stationary pressure vessel.
The invention is realized by the following technical scheme:
a method of inspecting a stationary pressure vessel, comprising the steps of:
step 1: measure theInner diameter R of pressure vessel, allowable stress amplitude of wall material of pressure vessel at service temperature
And the welding seam coefficient alpha of the pressure vessel, and calculating the theoretical thinnest allowable wall thickness of the pressure vessel by using the formula (1):
in the formula, D1The theoretical thinnest allowable wall thickness of the pressure container is shown, and P is the maximum bearing pressure of the pressure container;
step 2: measuring the thickness of the fixed pressure container by using a thickness gauge, and calculating the average actual wall thickness D of the container2Comparison of the average actual wall thickness D2And the thinnest allowable wall thickness D1If D is1≥0.8D2Then the pressure vessel can be judged to be in danger of leakage or explosion; if D is1＜0.8D2Entering step 3 for further detection;
and step 3: carrying out full-wall scanning on the pressure container by using an ultrasonic measurement method, determining the existing defects, positioning all the defects and marking;
and 4, step 4: performing ultrasonic time difference diffraction detection on the position with the defect to obtain the length and the height of the defect, and calculating the simulation size according to the length and the height of the defect to obtain the simulation size of the defect; screening out the crack with the largest simulation size, and recording the simulation size as D3；
Step 5, simulating the maximum size D of the defect3And the average actual wall thickness D2Making a comparison if D3≥0.75D2Then the pressure vessel can be judged to be in danger of leakage or explosion; if D is3＜0.75D2Then performing further detection of step 6;
step 6: measuring the elastic modulus, Poisson's ratio and yield strength of the material of the container wall, injecting a fluid with a preset pressure p into the pressure container, and performing a high-cycle crack propagation test, wherein the axial stress and the hoop stress of the inner wall surface of the pressure container can be expressed by the following formula (2) and formula (3):
σ1＝pR/4D2 (2)
σ2＝pR/2D2 (3)
in the formula, σ1Denotes axial stress, σ2Representing hoop stress;
calculating a stress intensity factor K of the defect crack according to the elastic modulus, Poisson's ratio, yield strength, axial stress and hoop stress of the material of the container wall;
and 7: calculating the propagation rate of the defect crack by using a Paris formula, wherein the specific formula is as follows:
wherein a represents a crack simulation size, N represents the number of stress cycles,
indicating the crack propagation rate, C, n is the material constant, A is the temperature coefficient;
step 8, according to the judgment in the step 5, the simulated size of the crack reaches 0.75D2And (3) judging that the crack is failed and has the risk of leakage or explosion, and integrating the formula (4) to obtain a service life prediction formula (5) of the defect crack:
in the formula, a0Is the initial value of the maximum defect crack simulated size obtained in step 4,
thereby determining the remaining life of the fixed pressure vessel.
Preferably, in step 3, during the ultrasonic scanning, the positions of the welding seam, the container corner, the joint and the like are scanned with emphasis.
Preferably, the defect crack length in step 4 is obtained by:
crack length was detected by D-scan of TOFD, calculated by equation (6):
wherein l is the length of the defect crack, Δ T is the time difference between the through wave in TOFD and the diffracted wave of the crack, c is the propagation speed of the ultrasonic wave in the container wall, and S is half of the distance of the probe center.
Preferably, the height of the defect crack in step 4 is obtained by:
crack height was detected by D-scan of TOFD, calculated by equation (7):
wherein h represents the height of the defect crack, t is the arrival time of the tip diffraction wave on the defect, Δ t is the time difference between the upper and lower tip diffraction waves in TOFD, c is the propagation speed of the ultrasonic wave in the vessel wall, and s is the probe center-to-center distance.
Preferably, in step 4, the simulated size of the defect is calculated by equation (8):
where e is the eccentricity of the crack centre from the centre of the container wall thickness and D2The average actual wall thickness of the container calculated in step 2.
Preferably, the fluid injected in step 6 is a gas or liquid stored in a stationary pressure vessel.
Preferably, the gas is natural gas and the liquid is gasoline or the like.
Compared with the prior art, the invention has the following beneficial effects:
firstly, judging whether the pressure container is damaged or not, wherein the steps are simple, instead of simply utilizing Paris to directly predict the service life of the crack, the pressure container is firstly preliminarily judged according to the comparison relation between the theoretical thinnest wall thickness and the average actual wall thickness, and whether the pressure container is in danger or not is judged; and then, comparing the average actual wall thickness with the maximum defect simulation size, and then, carrying out safety judgment on the pressure container with the thicker actual wall thickness, and finally, predicting the residual life of the cracks of the safe pressure container. The detection method for gradual detection and judgment saves detection cost and time, carries out safety detection on the fixed pressure container more intuitively and comprehensively, and also carries out omnibearing judgment on the pressure bearing capacity, the leakage capacity and the safety performance of the fixed pressure container more conveniently.
Compared with single methods such as magnetic powder, ray and ultrasonic time difference diffraction, the detection method provided by the invention makes more comprehensive judgment, does not use the height or length of a single defect crack, and calculates the simulation size, so that the relation between the crack size and the wall thickness is reflected more accurately. Meanwhile, a more accurate calculation mode is provided for the prediction of the residual life.
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FIG. 1 illustrates a method of testing a stationary pressure vessel in accordance with the present invention
Detailed Description
Example 1
For a petroleum storage tank made of 16MnR steel, the diameter of the petroleum storage tank is 7m, the measured actual average wall thickness is 30mm, the yield strength of the steel is 345MPa, the elastic modulus is 2.08MPa, and the Poisson ratio is 0.3, the storage tank is detected by the following specific steps:
measuring the internal diameter R of the pressure vessel, and the allowable stress amplitude of the wall material of the pressure vessel at the use temperature
And the welding seam coefficient alpha of the pressure vessel, and calculating the theoretical thinnest allowable wall thickness of the pressure vessel by using the formula (1):
in the formula, D1The theoretical thinnest allowable wall thickness of the pressure container is shown, and P is the maximum bearing pressure of the pressure container;
substituting the relevant parameters to obtain the thinnest allowable wall thickness of 20.6mm, and entering the step 3 because 20.6mm is less than 0.8 x 30mm, carrying out full-wall scanning on the pressure container by using an ultrasonic measurement method, determining the existing defects, and positioning and marking all the defects;
and 4, step 4: performing ultrasonic time difference diffraction detection on the position with the defect to obtain the length and the height of the defect, and calculating the simulation size according to the length and the height of the defect to obtain the simulation size of the defect; screening out the crack with the largest simulation size, and recording the simulation size as D3(ii) a The specific calculation method comprises the following steps:
crack length was detected by D-scan of TOFD, calculated by equation (6):
wherein l is the length of the defect crack, Δ T is the time difference between the through wave in TOFD and the diffracted wave of the crack, c is the propagation speed of the ultrasonic wave in the container wall, and S is half of the distance of the probe center.
The height of the defect crack is obtained by:
crack height was detected by D-scan of TOFD, calculated by equation (7):
wherein h represents the height of the defect crack, t is the arrival time of the tip diffraction wave on the defect, Δ t is the time difference between the upper and lower tip diffraction waves in TOFD, c is the propagation speed of the ultrasonic wave in the vessel wall, and s is the probe center-to-center distance.
The simulated size of the defect is calculated by equation (8):
where e is the eccentricity of the crack centre from the centre of the container wall thickness and D2And (3) measuring the average actual wall thickness of the container calculated in the step 2, wherein the simulation size of the maximum defect is 7.365mm which is less than 0.75 x 30mm after detecting the crack in the welding seam, injecting a fluid with a preset pressure p into the pressure container according to the elastic modulus, Poisson ratio and yield strength of the material of the container wall, and performing a high-cycle crack propagation test, wherein the axial stress and the circumferential stress of the inner wall surface of the pressure container can be expressed by the formula (2) and the formula (3):
σ1＝pR/4D2 (2)
σ2＝pR/2D2 (3)
in the formula, σ1Denotes axial stress, σ2Representing hoop stress;
calculating a stress intensity factor K of the defect crack according to the elastic modulus, Poisson's ratio, yield strength, axial stress and hoop stress of the material of the container wall;
then, calculating the propagation rate of the defect crack by using a Paris formula, wherein the specific formula is as follows:
wherein a represents a crack simulation size, N represents the number of stress cycles,
indicating the crack propagation rate, C, n is the material constant, A is the temperature coefficient;
finally, according to the judgment in the step 5, the simulated size of the crack reaches 0.75D2And (3) judging that the crack is failed and has the risk of leakage or explosion, and integrating the formula (4) to obtain a service life prediction formula (5) of the defect crack:
in the formula, a0Is the initial value of the maximum defect crack simulated size obtained in step 4,
thereby determining the remaining life of the fixed pressure vessel.
Finally, by calculation, N is 15734 times, i.e. the oil storage tank can also be filled 15734 times at a predetermined pressure and temperature, so that its maximum crack will propagate to 22.5mm, which is a contribution to leakage, and the tank should be repaired or decommissioned.
Meanwhile, when the subsequent detection is carried out by the same method, if the wall thickness of the tank body is smaller than 24mm or the simulated size of the maximum crack is higher than 0.75 time of the actual wall thickness due to corrosion and the like, the storage tank is required to be repaired or decommissioned to prevent accidents.
The above detailed description is merely illustrative of the preferred embodiments of the present invention and is not intended to limit the present invention. One skilled in the art, upon reading this disclosure, will appreciate that various modifications and changes may be made without departing from the scope of the present invention. The scope of the invention is defined by the claims.
Claims (4)
1. A method of inspecting a stationary pressure vessel, comprising the steps of:
step 1: measuring the internal diameter R of the pressure vessel, and the allowable stress amplitude of the wall material of the pressure vessel at the use temperature
And the welding seam coefficient alpha of the pressure vessel, and calculating the theoretical thinnest allowable wall thickness of the pressure vessel by using the formula (1):
in the formula, D1Represents the theoretical thinnest allowable wall thickness of the pressure vessel, and P is the maximum bearing pressure of the pressure vesselForce;
step 2: measuring the thickness of the fixed pressure container by using a thickness gauge, and calculating the average actual wall thickness D of the container2Comparison of the average actual wall thickness D2And the thinnest allowable wall thickness D1If D is1≥0.8D2Then the pressure vessel can be judged to be in danger of leakage or explosion; if D is1＜0.8D2Entering step 3 for further detection;
and step 3: carrying out full-wall scanning on the pressure container by using an ultrasonic measurement method, determining the existing defects, positioning all the defects and marking;
and 4, step 4: performing ultrasonic time difference diffraction detection on the position with the defect to obtain the length and the height of the defect, and calculating the simulation size according to the length and the height of the defect to obtain the simulation size of the defect; screening out the crack with the largest simulation size, and recording the simulation size as D3；
Step 5, simulating the maximum size D of the defect3And the average actual wall thickness D2Making a comparison if D3≥0.75D2Then the pressure vessel can be judged to be in danger of leakage or explosion; if D is3＜0.75D2Then performing further detection of step 6;
step 6: measuring the elastic modulus, Poisson's ratio and yield strength of the material of the container wall, injecting a fluid with a preset pressure p into the pressure container, and performing a high-cycle crack propagation test, wherein the axial stress and the hoop stress of the inner wall surface of the pressure container can be expressed by the following formula (2) and formula (3):
σ1＝pR/4D2 (2)
σ2＝pR/2D2 (3)
in the formula, σ1Denotes axial stress, σ2Representing hoop stress;
calculating a stress intensity factor K of the defect crack according to the elastic modulus, Poisson's ratio, yield strength, axial stress and hoop stress of the material of the container wall;
and 7: calculating the propagation rate of the defect crack by using a Paris formula, wherein the specific formula is as follows:
wherein a represents a crack simulation size, N represents the number of stress cycles,
indicating the crack propagation rate, C, n is the material constant, A is the temperature coefficient;
step 8, according to the judgment in the step 5, the simulated size of the crack reaches 0.75D2And (3) judging that the crack is failed and has the risk of leakage or explosion, and integrating the formula (4) to obtain a service life prediction formula (5) of the defect crack:
in the formula, a0Is the initial value of the maximum defect crack simulated size obtained in step 4,
calculating the residual life of the fixed pressure container;
wherein, the defect crack length in the step 4 is obtained by the following method:
crack length was detected by D-scan of TOFD, calculated by equation (6):
wherein l is the length of the defect crack, Delta T is the time difference between a through wave in TOFD and a diffracted wave of the crack, c is the propagation speed of the ultrasonic wave in the container wall, and S is half of the distance of the center of the probe;
the height of the defect crack in the step 4 is obtained by the following method:
crack height was detected by D-scan of TOFD, calculated by equation (7):
in the formula, h represents the height of a defect crack, t is the arrival time of a tip diffraction wave on the defect, delta t is the time difference of upper and lower tip diffraction waves in TOFD, c is the propagation speed of an ultrasonic wave in a container wall, and s is the center distance of a probe;
in step 4, the simulated size of the defect is calculated by equation (8):
where e is the eccentricity of the crack centre from the centre of the container wall thickness and D2The average actual wall thickness of the container calculated in step 2.
2. The method as claimed in claim 1, wherein the ultrasonic scanning is performed to scan the weld, the container corner, and the joint with emphasis.
3. The method according to claim 1, wherein the fluid injected in step 6 is a gas or a liquid stored in the fixed pressure vessel.
4. The method of claim 3, wherein the gas is natural gas and the liquid is gasoline.
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| CN112097832A (en) * | 2020-09-09 | 2020-12-18 | 苏州华碧微科检测技术有限公司 | Method for analyzing failure of pressure container |
| JP2022090739A (en) * | 2020-12-08 | 2022-06-20 | アクア株式会社 | Inspection method for accumulator |
| CN113109160B (en) * | 2021-04-07 | 2022-10-04 | 南京金创有色金属科技发展有限公司 | Safety assessment technical method for pressure container with over-design service life |
| CN113884044A (en) * | 2021-09-18 | 2022-01-04 | 华电电力科学研究院有限公司 | Intelligent detection method and detection device for wall thickness of pressure container |
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